Liebert CHALLENGER 3000 User Manual

Precision CoolingFor Business-Critical ContinuityLiebert Challenger™ 3000Operation & Maintenance Manual - 3 & 5 Ton, 50 & 60Hz

Introduction21.2 Start-Up ProcedureBefore beginning start-up, make certain that unit was installed according to the instructions in the Installation M

Operation with Advanced Microprocessor Controls32.0 OPERATION WITH ADVANCED MICROPROCESSOR CONTROLSThe advanced microprocessor (A) control for your Li

Operation with Advanced Microprocessor Controls4Figure 2 Advanced microprocessor (A) control for Challenger 300072°F 50%RHCoolingDehumidifyingNo Alarm

Operation with Advanced Microprocessor Controls52.2 Status DisplayThe display normally shown includes the present room temperature, humidity, active s

Operation with Advanced Microprocessor Controls62.4.4 Run Hours LogThe total operating hours of all major components in the unit can be monitored from

Operation with Advanced Microprocessor Controls72.5.2 Setup SystemThe Setup System menu includes the following selections:• SETUP OPERATION• SELECT OP

Operation with Advanced Microprocessor Controls8Table 2 lists the setup functions, their factory default values and the allowable programming ranges.S

Operation with Advanced Microprocessor Controls9Select Control Type • Intelligent (Chilled Water only)• Proportional (all unit types)• Tunable PID (Ch

Operation with Advanced Microprocessor Controls10Enable Alarms—Each individual alarm can be selected to be ENABLED (annunciated audibly, visu-ally, an

Operation with Advanced Microprocessor Controls11Analog SetupFor installation of analog sensors, see 4.5.1 - Connecting the Analog Sensors.After selec

Operation with Advanced Microprocessor Controls122.5.3 Run DiagnosticsBy selecting Run Diagnostics, maintenance personnel can check system inputs, out

Operation with Advanced Microprocessor Controls132.5.4 Change PasswordsThe display prompts you to enter a three digit password when making changes. Th

Operation with Advanced Microprocessor Controls142.8.2 Non-Volatile MemoryAll critical information is stored in nonvolatile memory. Setpoints, setup p

Operation with Advanced Microprocessor with Graphics Control153.0 OPERATION WITH ADVANCED MICROPROCESSOR WITH GRAPHICS CONTROLThe advanced microproces

Operation with Advanced Microprocessor with Graphics Control16Figure 4 Advanced microprocessor with graphics control menu* Select Control Algorithm av

Operation with Advanced Microprocessor with Graphics Control173.2 Status DisplayThe normal status screen is divided into two sections, a right half an

Operation with Advanced Microprocessor with Graphics Control183.4.3 Setup AlarmsThe list of alarms may be reviewed using the UP/DOWN keys. Any alarm m

Operation with Advanced Microprocessor with Graphics Control193.4.4 Setup Custom AlarmsSelecting SETUP CUSTOM ALARMS will step to the following menu:•

Operation with Advanced Microprocessor with Graphics Control203.5 Operating StatusThe Operating Status is intended to provide the user with displayed

Operation with Advanced Microprocessor with Graphics Control21Auto Restart DelayThis feature allows for the unit to restart automatically after a loss

iTABLE OF CONTENTS1.0 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Operation with Advanced Microprocessor with Graphics Control223.7.2 Select OptionsThe following table is a list of options which should match the opti

Operation with Advanced Microprocessor with Graphics Control233.7.6 Select Humidity Sensing ModeThe user may select between RELATIVE (direct) and ABSO

Operation with Advanced Microprocessor with Graphics Control243.8.1 Show InputsWith the unit on and the fan running, the input state for the following

Operation with Advanced Microprocessor with Graphics Control253.8.4 DIP SwitchesThe DIP switch settings can be reviewed from the display panel. Changi

Operation with Advanced Microprocessor with Graphics Control263.11 Analog/Digital InputsSelecting ANALOG/DIGITAL INPUTS steps to the following menu:•

Operation with Advanced Microprocessor with Graphics Control273.12.1 View 24 Hour Run Time HistoryThe history of each load for every hour during the p

Operation with Advanced Microprocessor with Graphics Control283.13.2 Nonvolatile MemoryAll critical information is stored in nonvolatile memory. Setpo

System Performance with Advanced Microprocessor Controls294.0 SYSTEM PERFORMANCE WITH ADVANCED MICROPROCESSOR CONTROLSThis section provides details on

System Performance with Advanced Microprocessor Controls304.1.3 Cooling Operation1-Step Cooling, Compressorized Direct Expansion (DX) SystemsCooling a

System Performance with Advanced Microprocessor Controls314.1.4 Heating OperationElectric ReheatThe two heat stages are activated when the temperature

ii3.7.1 Setup Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

System Performance with Advanced Microprocessor Controls324.2.4 Humidification OperationSystem ActivationThe humidifier (infrared or steam) is activat

System Performance with Advanced Microprocessor Controls33A suggested tuning procedure is as follows:1. Initially adjust the integral and derivative s

System Performance with Advanced Microprocessor Controls344.4 Load Control Features4.4.1 Short Cycle ControlThe control system monitors the compressor

System Performance with Advanced Microprocessor Controls35Figure 5 Analog input jumpers4.5.2 Water Detection DisplayThe water detection display is des

System Performance with Advanced Microprocessor Controls36Physical ConnectionsFigure 6 shows the 4-20 mA output of LT750 connected to Analog Input #1

System Performance with Advanced Microprocessor Controls374.6 CommunicationsThe control system uses a two-wire, RS-422 channel to communicate with rem

Alarm Descriptions385.0 ALARM DESCRIPTIONSThe Advanced Microprocessor (A) and the Advanced Microprocessor with Graphics (G) Control sys-tems will audi

Alarm Descriptions395.1.2 Compressor OverloadAn optional tri-block overload device can be used for the compressor. Compressor overload may be manual o

Alarm Descriptions405.1.8 High Temperature and Low Temperature (Simultaneously)If these two alarms are displayed at the same time, the temperature inp

Alarm Descriptions415.1.16 Short CycleOn compressorized systems, if the compressor has exceeded 10 cooling starts in one hour or if the compressor has

iii4.4.2 Sequential Load Activation Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344.5 Addition

Component Operation and Maintenance426.0 COMPONENT OPERATION AND MAINTENANCE6.1 System Testing6.1.1 Environmental Control FunctionsThe performance of

Component Operation and Maintenance43FirestatThe optional firestat is a bimetal operated sensing device with a normally closed switch. This device wil

Component Operation and Maintenance44The zone leak detection kit provides leak detection for a defined zone. This kit is ideal for perimeter sensing o

Component Operation and Maintenance456.3 Blower PackagePeriodic checks of the blower package include: belt, motor mounts, fan bearings, and impellers.

Component Operation and Maintenance466.4 Refrigeration SystemEach month, the components of the refrigeration system should be inspected for proper fun

Component Operation and Maintenance476.4.4 Thermostatic Expansion ValveOperationThe thermostatic expansion valve performs one function. It keeps the e

Component Operation and Maintenance486.4.6 Air Cooled CondenserRestricted airflow through the condenser coil will reduce the operating efficiency of t

Component Operation and Maintenance496.4.7 Water/Glycol Cooled CondensersCoaxial CondenserEach water or glycol cooled module has a coaxial condenser w

Component Operation and Maintenance50High Pressure Valve - 350 PSIG System (2413 kPa) for 3 Ton Units (Metrex Valve)Adjustment—The valve may be adjust

Component Operation and Maintenance516.4.8 Compressor Functional CheckThe following diagnostic procedure should be used to evaluate whether the compre

iv6.5 Humidifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 536

Component Operation and Maintenance52Electrical FailureAn electrical failure will be indicated by a distinct pungent odor. If a severe burnout has occ

Component Operation and Maintenance536.5 Humidifier6.5.1 Infrared HumidifierDuring normal humidifier operation, deposits of mineral solids will collec

Component Operation and Maintenance54Autoflush Infrared Humidifier Cleaning SystemThe autoflush system will periodically flush the humidifier pan with

Component Operation and Maintenance55Operation1. During start-up, when the humidity control calls for humidification, the fill valve opens and allows

Component Operation and Maintenance56Replacing the CanisterOver a period of operation, the humidifier electrodes become coated with mineral solids. Th

Component Operation and Maintenance57Figure 14 Canister replacementCircuit Board AdjustmentsHumidifier operation is governed by the humidifier control

Troubleshooting587.0 TROUBLESHOOTINGUse this section to assist in troubleshooting your unit. Also refer to 5.0 - Alarm Descriptions. Sug-gestions are

Troubleshooting59Table 23 Compressor and refrigeration system troubleshootingSymptom Possible Cause Check or RemedyCompressor will not startPower off

Troubleshooting60FloodingDefective or improperly set expansion valveIncrease superheat or replace valveEvaporator fan motor or belt Correct problem or

Troubleshooting61Table 24 Dehumidification troubleshootingSymptom Possible Cause Check or RemedyNo dehumidificationControl not calling for dehumidific

vFIGURESFigure 1 Advanced microprocessor control panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Troubleshooting62Table 27 Steam generating humidifier troubleshootingSymptom Possible Cause Check or RemedyFalse canister full indicationFoamingCheck

Troubleshooting63Excessive arcing in the canisterDrain valve clogged or defectiveVerify that drain valve operates freely when activated. Clean valve a

Monthly Maintenance Inspection Checklist648.0 MONTHLY MAINTENANCE INSPECTION CHECKLISTDate:_______________________________________ Prepared by:_______

Semiannual Maintenance Inspection Checklist659.0 SEMIANNUAL MAINTENANCE INSPECTION CHECKLISTDate:________________________________________ Prepared by:

Semiannual Maintenance Inspection Checklist66

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Introduction11.0 INTRODUCTION1.1 System DescriptionsChallenger 3000™ Liebert environmental control systems are available in several configurations. Ea